Crushing Behavior of Cylindrical Glass Fiber-Reinforced Composite Crash Boxes with Different Fiber Winding Angles: An Experimental and Multi-criteria Decision-Making Approach Using TOPSIS

Abstract This study examines the energy absorption characteristics of composite crash boxes made from glass fibers wound at different angles, aiming to enhance vehicle safety in collisions. Nine type crash box samples were produced with varying fiber winding angles and subjected to quasi-static compression tests. The results demonstrated that the crash box with a 30° fiber winding angle exhibited the highest energy absorption capacity. The 30° winding angle enhances energy absorption because of its optimal balance between axial load-bearing capacity and shear deformation, promoting controlled crushing and improved crashworthiness, which makes it more effective than higher-angle laminates prone to localized delamination and brittle failure. Despite this, its crushing force efficiency was lower compared to other samples. The other samples displayed varying energy absorption capabilities, with the (+ 60, − 60)° wound sample showing the lowest energy absorption and crushing force efficiency. The findings emphasize the impact of fiber winding angles on the energy absorption performance of the collision boxes, highlighting a significant relationship between these angles and the maximum deformation force. Additionally, the study reveals that the average deformation force has a direct influence on the total energy absorption capacity. A TOPSIS-based optimization approach was used to improve crashworthiness by balancing four equally weighted parameters, maximizing energy absorption, mean crushing force, and crushing force efficiency while minimizing the maximum crushing force. This research contributes to the understanding of the mechanical behavior of composite crash boxes and provides valuable insights into optimizing their design for better impact resistance.